Building

ABSTRACT

A building employing prefabricated room-enclosing modules which function also as box-shaped horizontal beams and ties for connecting vertical weight-supporting columns into a rigid framework. The columns are preferably concrete members which are poured in place into spaces formed between the modules. The inter-module spaces include vertical chases and horizontal plenums which are in communication with each other and with a heating/cooling plant output, to form an air jacket which surrounds each module over a plurality of its exterior surfaces, and operates as an effective radiant heat exchanger therewith. The heated or cooled air is ultimately discharged into the interior occupancy space of the modules, so as to provide a combination radiant and convective heating/cooling system. The interior occupancy space of the modules is sealed during on-site construction, so that no workmen may enter. The interior of the modules is finished prior to shipment to the construction site, including the installation of all interior service facilities and connecting lines leading from such facilities to a special chamber which is accessible from the exterior of the module. At the construction site workmen can enter this chamber to connect the modules to service risers which extend vertically through a duct formed by vertical alignment of the module chambers, and upper and lower hatchways thereof.

[ 3,750,366 Aug. 7, 1973 United States Patent 91 Rich, 'Jr. et al.

1,083,552 9/1967 Great 52/79 BUILDING [75] Inventors: Frank D. Rich,Jr., Darien;

Primary Examiner-Henry C. Sutherland Attorney- -l-laynes N. JohnsonAlexander D. McDonald, Glenbrook, both of Conn.

Assignee: F. D. Rich Housing Corp.,

[57] ABSTRACT A building employing prefabricated room-enclosingStanford,

Conn.

[22] Filed: July 16, 1971 [21] Appl. No.: 163,274

modules which function also as box-shaped horizontal beams and ties forconnecting vertical weightsu ortin columns into a ti id framework. Thecol- Rehted Apphcamm Data TEES are preferably concre te members whichare COllilllllQtlOlhlfl Pfll't 0f Ser. NO. 4,156, Jan. 19, 1970, pouredin place into spaces formed between the modaband'medules. Theinter-module spaces include vertical chases and horizontal plenums whichare in communication with each other and with a heating/cooling plantoutput, to form an air jacket which surrounds each module over aplurality of its exterior surfaces, and operates as an effective radiantheat exchanger therewith. The heated or cooled air is ultimatelydischarged into the interior occupancy space of the modules, so as toprovide a combination radiant and convective heatinglcooling system. Theinterior occupancy space of the modules is sealed during on-siteconstruction, so that no workmen may enter. The interior of the modulesis finished prior to shipment to the construction site, including theinstallation of all interior service facilities and connecting linesleading from such facilities to a special chamber which is accessiblefrom the exterior of the module. At the construction site workmen canenter this chamber to connect the modules to service risers which extendvertically through a duct formed by vertical alignment of the modulechambers, and upper and lower hatchways thereof.

11 Claims, 22 Drawing Figures Lowe eta1.. 4/1970 Van Hezik..

Rohrer........

France........... 6/1964 Belgium.........

m Ilia SC FFE 0 226 7 656 9 999 l 111 ll/ 6 255 1 6/1910 Conzelman I2/1914 Donaldson.. 3,514 6/1970 Comm 3,613 10/1971 FOREIGN PATENTS ORAPPLICATIONS 042 12/1967 'France...........

n i v i a a PAIENTEU 3.750.366

sum 01 or 13 INVENTORS FRANK D.RICH JR. ALEXANDER D. MCDONALDPATENIEDAUB ms SHEET 02 0 13 INVENTORS FRANK D RICH JR. ALEXANDER D.McDONALD PAIENIEUAUB 1191a sum uu or 13 INVENTORS' FRANKDRICH JR.ALEXANDER D. McDONALD BY 08 mo ATTY.

PAIENIED AUG 7 I973 sum as 0F :3

INVENTORS FRANK D. RICH JR. ALEXANDER D. McDONALD PATENIED sum as or 13naw .1...

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PAIENIEU 7W5 3.750.366

sum 070f13 2| L W E 8 :5 E X INVENTORS FRANK D. RICH JR.

ALEXAN DER D. McDONALD PATENIED 3.750.366

sum U8UF13 INVENTORS FRANK D RICH JR. ALEXANDER D. McDONALD PAIENIED3,750,366

sum 0s 0F 13 mom m &\ BN N 1: T &9

COM NON 1 3 mom 2 01 Now oom INVENTORS FRANK D. RICH JR. ALEXANDER D.McDONALD PATENTEU 71975 sum 10 or 13 INVENTORS FRANK D. RICH JR.ALEXANDER D. McDONALD PATENTED M19 7 sum .11 0F 13 INVENTORS FRANK D.RICH JR. ALEXANDER D. McDONALD BUILDING CROSS-REFERENCE This applicationis a continuation-in-part of now abandoned U.S. patent application Ser.No. 4,156 filed Jan. 19, 1970 entitled Improved Building.

FIELD OF THE INVENTION This invention relates generally to construction,and is particularly applicable to high rise apartment buildingsemploying prefabricated room modules.

BACKGROUND OF THE INVENTION There is a great deal of literatureconcerning the advantages of prefabricated room-enclosing boxes ormodules, and other new techniques such as the use of pou'red-in-place orprefabricated and post-tensioned structural columns to support high risebuildings. It appears, however, that the modular box technique has notyet become standard practice in building construction, and therefore hasnot been developed to its fullest potential.

Since economics is the key to the adoption of any new constructiontechnique, it appears that the savings presently obtainable by the useof prefabricated room modules are not sufficient. It may be, therefore,that it is necessary for these modules to combine a plurality offunctions as a means of achieving still greater construction economies.

Certain problems in particular have been encountered in usingprefabricated room modules in high rise buildings. The conventionalapproach to the construction of multi-story buildings by this method isto stack the modules one upon the other. Thisrequires each module tohave sufficient structural strength in the vertical direction to supportthe weight of all the modules above it. If the modules are identical,for ease of mass production, then they must either be so heavy (to meetthe strength requirements of the lower stories) that material is wastedon the upper stories, or they must be so weak as to limit the maximumheight of the building. If different types of modules are used for theupper and lower stories, on the other hand, then some of the advantagesof mass production are sacrificed, and problems of inventory and storageare intensified.

In order to overcome these difficulties it is necessary to have separatevertical columns which support the weight of the modules on the upperfloors. This can be accomplished by means of a conventional structuralframework employing vertical columns connected together by horizontalbeams and ties, but the erection of such a framework is costly andtime-consuming. It has been previously suggested, as in French Pat. No.l,244,983, that the modules can be made to do double duty by functioningas pouring forms, where the columns are made of concrete poured into theinterstitial spaces between horizontally spaced modules. Moreover, ifthe entire space between such modules is not taken up by poured concretethe remaining space can be used for distribution of various serviceconnections throughout the building. This approach is useful, but doesnot go far enough in extracting all possible economies from the boxmodule concept; and in particular it still requires a completestructural framework. See, for example, U.S. Pat. No. 3,514,910 of Comm.

In construction projects generally, whether or not they employ the boxmodule approach, a persistent problem has been dirtying of the interiorroom space when workmen enter to perform interior construction and/orfinishing work, and to make service connections to on-site facilitiessuch as electricity, water, waste disposal, and fuel. Unavoidably, mudand debris are trackedinto the interior of the new building,necessitating a thorough cleaning operation before the building is readyto receive occupants. This is unavoidable if the interior rooms areconstructed on the site; but even with the prefabricated room moduleapproach, as it has been practiced until now, it is necessary to enterthe modules to make service connections thereto.

It was recognized some time ago that superior heating and cooling ofinterior living space could be achieved by conducting heated and cooledair through spaces formed for that purpose in the walls, floors andceilings. Not only is this expedient suggested in U.S. Pat. No.2,107,523 of Coe; but it was used in primitive form by the ancientRomans who employed a hypocaust structure, i.e., an under-floor plenumand inwall ducts, to heat their public baths. See Hypocaust, ChambersEncyclopaedia, I959 Edition, Vol. 7, P. 351-52 (published by GeorgeNewnes, Ltd., London) for a description of the Roman structure; and fora modern equivalent see Plenum Floor System for Basementless Houses by0.1. Stout, Better Building Report No. 4, College of Engineering,Pennsylvania State University, University Park, Pa. This approach heatsor cools the interior room surfaces, so that the occupants are heated orcooled by radiation. In addition, the heated or cooled air may beconducted into the room interior so that convective heating/coolingeffects are superimposed upon the radiative. The individual inwall ductssuggested by Coe, Stout and the Roman architects to achieve this effect,however, are quite laboriously molded into the walls and/or incorporatedinto the floors by outmoded and uneconomical construction procedures.

THE INVENTION The present invention goes much further in extractingconstruction economies from the room module approach. It contemplatesthat the room modules, in addition to enclosing interior space andfunctioning as molds for poured concrete columns, shall also function asthe horizontal structural beams of the building framework. In order toperfonn this function, the modules are connected at opposite ends to thevertical columns, and have sufficient strength in the direction of theirlongitudinal axes to hold the columns in fixed relationship. Inaddition, the modules may also have sufficient structural strength inthe direction of their transverse horizontal axes to serve as ties,which connect the vertical columns in a second horizontal direction.

In another aspect of the invention, during prefabrication the roommodules are completely finished internally and provided with allnecessary interior service facilities and connecting lines. Then thedoors and windows of the modules are sealed so that no one will enterafter the modules are delivered to the construction site. A specialservice connection chamber is provided, which is accessible from outsidethe module. All the service lines leading from the interior of themodule terminate in this chamber, which the on-site workmen can enter tomake connections without entering the living space. In order to form avertical duct through which service risers can extend through thebuilding,

each of the chambers has upper and lower hatchways, and the chambers andhatchways of each vertical bank of modules are vertically aligned.

In this building, the spaces between horizontally adjacent andvertically adjacent modules contain heated or cooled air, resulting inan advantageous hypocaust type of radiative temperature conditioningsystem, and also providing convenient channels for conducting theconditioned air into the room interiors for convective as well asradiative heating or cooling. In this respect, the present building issimilar to that seen in the Coe patent cited above. According to thepresent invention, however, the wall chases and the plenums betweenfloors and. ceilings which are required for this type of temperatureconditioning system are inherently formed economically and easily byhorizontal and vertical spacing apart of the pre-cast room modules as aresult of the construction method described herein.

BRIEF DESCRIPTION OF THE DRAWINGS FIG. 1 is a perspective view, withparts broken away for clarity of illustration, of a partiallyconstructed high rise apartment building in accordance with thisinvention.

FIG. 2 is an end elevational view of a single prefabricated module ofthe type used in constructing the building of FIG. 1.

FIG. 3 is a fragmentary top plan view of the building of FIG. I, showingthe use of bulkheads to segregate a portion of the inter-module spacefor use as a concrete pouring form for the construction of columns.

FIG. 4 is a fragmentary perspective view showing laterally projectinghaunches formed on the poured concrete columns, for the support of themodules immediately above, and the plenum spaces thus defined betweenmodules spaced vertically by the haunches.

FIG. 5 is a fragmentary vertical section of the building of FIG. 1,taken transversely of the modules, and

showing the tapering of module walls and segments of showing decreasesin the overall cross-sectional size of each successive column segment asthe building progresses upwardly in height.

FIG. 7 is a fragmentary, partially exploded, perspective view, withparts broken away for clarity of illustration, of a pair of outriggerbeams'and an exterior gallery to be assembled therewith in the buildingof FIG. 1.

FIG. 8 is another fragmentary perspective view of an alternativebuilding in accordance with this invention, illustrating the formationof outrigger beams as integral parts of the modules, and showing howthese beams support exterior galleries which serve as a common hallwayfor the various apartment suites in the building.

FIG. 9 is an exploded perspective view, with parts broken away forclarity of illustration, of three separate modules which cooperate witheach other to provide the elevator, interior hall, and stairwayfacilities for the buildings of the preceding figures.

FIG. 10 is a perspective view, with'parts broken away for clarity ofillustration, showing the service connection chamber and other featuresof one of the modules in the buildings represented in the previousfigures.

FIG. I1 is a perspective view of the module of FIG. 10, showing thedistribution of electrical cables across the top of the module andextending back into the service connection chamber.

FIG. 12 is a fragmentary perspective view of one form of edge junctionbetween upper and lower modules, designed to seal the edges of theplenum spaces formed between vertically spaced modules.

FIG. 13 is a fragmentary perspective view, with parts broken away forclarity of illustration, showing a partition for dividing the plenumspace into separate chambers associated with individual apartmentsuites.

FIGS. 14 and 15 are perspective views of segments of an alternative formof columns for the buildings of the preceding figures, with means forpost-tensioning.

FIG. 16 is another perspective view of a similar column segment havingan integrally cast outrigger beam for supporting the exterior gallery.

FIG. 17 is a perspective view of an exterior wall panel for use inconstructing an end wall for the buildings of the preceding figures.

FIG. 18 is a perspective view of portions of a pair of such wall panelsattached to the sides of the modules, and defining a space between thewall panels and the modules, into which concrete may be poured.

FIG. 19 is a perspective view of the T-shaped bulkhead tops which areused to form haunches at the top of each poured concrete column segment.

FIG. 20 is a perspective view of doorway hardware used withcommunicating rooms of different modules.

FIG. 21 is a nomograph quantitatively analyzing the heating performanceof a hypocaust type radiantconvective temperature conditioning system inaccordance with this invention.

FIG. 22 is a similar nomograph, but relates to cooling performance.

The same reference numerals designate the same elements throughout theseveral views of the drawing.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS A high rise apartmentbuilding in accordance with this invention comprises a plurality ofindividual prefabricated modules 12 arranged in a vertically andhorizontally extending formation. These modules serve the basic purposeof enclosing interior room 14. In addition, however, they performseveral other functions which are of great importance in deriving themaximum economic benefit from the modular concept; i.e., they constitutethe horizontal beams extending across the width of the building (in thedirection of the longitudinal axes of the modules) which cooperate withupright supporting columns 16 to form a rigid rectangular framework.Such columns and framework are required for a high rise building.

Such beams do not have the usual I-shaped beam cross-section employed inconventional building construction. The modules I2 are in effect large,hollow box-shaped beams, in which the flanges" are a ceiling plate 18and a floor plate 22; the webs" are two wall plates 20; and the interiorspace surrounded by these four plates is the interior living area of thebuilding. In order to develop sufficient longitudinal rigidity andductility for the modules to function as beams, all four plates arepreferably cast of concrete grout material having conventional weldedwire reinforcing mesh embedded therein.

work. Note also that the four plates 18, 20 and -22 are r 5 eachstiffened by respective integrally cast concrete ribs 52, 40 and 54,which in turn are reinforced by steel rods embedded therein, as forexample the rods 41 seen in FIG. 3.

In a preferred embodiment of the invention the box beam modules 12 servea further function by defining forms in which the vertical columns 16can be cast by pouring a suitable concrete material into the spacesbetween horizintally spaced modules. Once the concrete hardens, it formsstrong structural members capable of supporting the weight of the uppermodules 12. Thus the lower modules are spared the necessity forsupporting the weight of the modules above them. Consequently, buildingsconstructed in accordance with this invention can attain as great aheight as any other concrete-frame building, using mass-producedidentical modules on each story.

In the process of construction of the illustrated building, first aplurality of poured concrete footings 30 (FIG. 5) are constructed in theground 32, and a horizontally projecting haunch structure 34 is castintegrally therewith by means of conventional wood pouring forms aboveground level. Next, the first level of prefabricated modules 12 isplaced upon the haunches 34, which are designed to serve as support padstherefor. In FIG. 5 only one support pad 34 is shown for each module 12,but it will be appreciated that there are at least four such supportpads for each module, appearing at the corners thereof. The first levelof modules 12.1 and 12.2 are spaced apart laterally as seen in FIG. 5,i.e., in the direction of the width of the modules, leaving a spacetherebetween into which a first level concrete column segment 16.1 canbe poured. As a part of the pouring of segment 16.1, a next level haunchor support pad is formed at thetop of column segment 16.1, by meansdiscussed subsequently. Upon these haunches 34 are placed the secondtier of modules 12.3 and 12.4, also in horizontally spaced relation topermit the pouring of a second level concrete column segment 16.2. Thelatter similarly is integrally cast with a third level set of haunches34, upon which is erected still another tier of modules 12.5 and 12.6,and the next level poured concrete column segment 16.3. This process iscontinued through additional tiers of modules such as 12.7 and 12.8, andadditional concrete column segments such as 16.4, until the desirednumber of stories has been erected.

It will be appreciated that the laterally projecting concrete haunchstructures 34 are the members which each directly support the weight ofthe tier of modules 12 immediately above them, but the module weightload is transferred by the haunches 34 to the entire vertical length ofcolumn 16 therebelow. As is conventional in' poured concreteconstruction processes, the individual column segments 16.1 through16.4, etc. are reinforced by means of the usual steel rods 36 which areput in place before the pouring operation, and ultimately are embeddedin the concrete. Usually a length of the rods 36 is allowed to projectabove each individually poured segment of the columns 16, and issubsequently embedded in the next column segment above, as a means ofsecuring the segments together.

An additional feature of this invention results in a substantialstrengthening of the molds, i.e., the module walls 26, without wastingany grout material. When concrete is poured to a substantial depth, asis done here toform the column segments 16.1, 16.2 etc., the hydrostaticpressure exerted on the module walls 20 near the bottom of the mold isconsiderably greater than it is near the top of the mold. To resist thatpressure, the module walls are made thick at the lower region 26A. Butthat thickness would be unnecessary, and wasteful of material, at theupper region 208; thus the module walls are tapered upwardly as seen inFIG. 5. Consequently each individually poured concrete column segment16.2, etc. is narrower at its lower region 16A than at its upper region168. This results in a complementary tapering of the module walls 20 andcolumn segments 16.2 etc., which has advantages in securing the modules12 and columns 16 together so that they function as a unified buildingframework. When the weight of the upper stories bears down on thecolumns 16, a certain amount of compression of the columns takes place.Consequently, the slanted surfaces of each column segment 16.2 etc.wedge downwardly against the complementary slant of the adjacentsurfaces of the module walls 20, thus tending to bind the columns 16 andmodules 12 together. Moreover, the effective column thickness forload-bearing purposes is that of the poured material 16.2 plus that ofthe two adjacent module walls 20 to which the poured material 16.2adheres.

If the total height of the building requires the columns 16 to havemaximum load-bearing capacity, the columns can extend along the entirehorizontal length of the modules 12; i.e., they can occupy the entirelength of the cavity between modules. However, a smaller columncross-section is adequate for an apartment building of ten stories, forexample; and considerable concrete material can be saved if the columns16 are confined to only a portion of the horizontal extent of theirinter-module spaces. This is best accomplished, as illustrated in FIG.3, by inserting expendable bulkheads 42, preferably inexpensive woodenplanks, vertically into the space 64 between the side plates 20 of twohorizontally spaced modules 12. A convenient way of bracing the woodenbulkhead planks 42 against the hydrostatic pressure of the pouredconcrete is by placing them against confronting pairs of vertical ribs66.1 and 410 .3. The entire inter-module space M is thus divided intoregions 44.1 and 64.2. The first region 44.1 is the one into which thesteel reinforcing rods 36 are inserted, and the material of the concretecolumns 16 is poured. The remaining portion .2 of the inter module spaceremains free of concrete, and thus constitutes a vertical chase which isuseful as a vertical distribution conduit for centrally heated or cooledair, or air employed for ventilation.

As seen in FIG. 6, an additional saving of concrete can be achieved bydecreasing the width of successive concrete column segments 16.1, 16.2,etc., as the building rises in height, reflecting the fact that eachsuccessively higher segment of the concrete columns 16 bears the weightof a smaller number of stories above it. The described decrease incolumn width on successive floors may be achieved, while using moduleswith identical rib spacing on each floor of the building, by selectingprogressively thicker bulkhead planks 42 to restrict the concrete pourto smaller portions 44.1 of the inter-module spaces 44 as the buildingincreases in height.

During the pouring of each column segment 16.1, 16.2, etc. the requiredhaunch or support pad 34 is formed at the top of the segment within thespace defined by the ceiling plates 18 of two adjacent modules such as12.1 and 12.2 (FIG. 19), special extensions 24.1 formed on the screedribs 24 of those modules, and T-shaped heads 42.1 formed at the tops ofthe bulkhead planks 42 to bridge between the screed ribs 24. The haunchpouring form thus defined is filled to a level slightly above the screedrib ex-tensions 24.1 and bulkhead extensions 42.1 (stiff concretematerial being used to prevent spillover) so that the haunch 34 becomesthe furthest upward projecting, and therefore the weightbearing, member.

The haunches so formed serve not only to support the prefabricatedmodule immediately above, but also serve to space apart each pair ofvertically consecutive modules to form a plenum space therebetween. Thusone of the laterally projecting haunches 34 spaces apart a lower levelmodule 12.1 and an upper level module 12.3 immediately above it, so thatbetween the ceiling plate 18 of the lower module and the floor plate 22of the upper module there is formed a horizontally extending plenumspace 50 which is useful for the distribution of air for heating,air-conditioning or ventilating purposes to each of the apartmentswithin the building.

Thus far we have pointed out a number of different functions which areall performed by the modules 12; i.e., they provide interior spaceenclosures which do not have to be fabricated on the site, they serve asconvenient pouring forms for the concrete columns, they form thehorizontal structural beams for the building framework, they definevarious horizontal plenums 50 and vertical chases 44.2, and they easethe problems of designing a high rise building because they are notrequired to bear the load of all the modules above them. In addition,however, they also serve the further function of tying the columns 16together in a direction parallel to the transverse horizontal axes ofthe modules. As seen in FIGS. 1, 4 and 8, each module ceiling plate 18is formed with exterior stiffening ribs 52, while each module floorplate 22 is formed with exterior stiffening ribs 54. These ribsstrengthen the module plates in a transverse direction so that they areable to serve as ties; i.e., structural members which connect thecolumns 16 in a transverse horizontal direction to complete the rigidityof the structural framework formed by the columns 16 and modules 12.

Thus, as seen in FIG. 8, a given module 12.9 ties together a pair oftransversely spaced columns 16.8 and 16.9 to restrain them from movingindependently of each other in the horizontal direction. In aconventional building framework the vertical load-bearing columns mustnot only be connected together in a first horizontal direction by anumber of beams, but they must also be connected together in a secondhorizontal direction by a plurality of ties. The present inventionpermits a builder to dispense entirely with separate beam and tiemembers, and to rely only on the modules 12 to perform both functions.Consequently an elaborate cage of beams and ties is entirely replaced bya plurality of modules 12 whose presence is required for space enclosurepurposes in any event.

The particular illustrative building embodiment described herein is anapartment house which has an exterior gallery at each floor serving asthe common hallway providing access to individual apartment suites. Thelength of the building extends parallel to the transverse axes of theindividual modules 12 and the exterior galleries 60 run along the lengthof the building, supported by horizontally projecting outrigger beams62. As seen in FIG. 8, the exterior galleries provide access throughmain entrance doorways 64 to each apartment suite. These doorways, likethe nearby windows 66, are formed in curtain walls 68 made of metal orany other suitable conventional construction material and constructedacross the otherwise open end of each module 12 to form the side wall ofthe building. These curtain walls would normally be installed at themodule factory.

FIG. 7 illustrates how the outrigger beams 62 may be separately cast ofconcrete, embedded in the poured concrete columns 16, and anchoredtherein by upwardly and downwardly projecting bolts 70, one of which isvisible in FIG. 7. Alternatively, the outrigger beams may be formedintegrally with the module side walls 20 as illustrated in FIG. 8. Ineither case the exterior gallery rests upon the outrigger beams, andfits horizontally into mating engagement with a kerf 72 (FIG. 7') formedat the front edge of the floor plate 22 of the module 12 immediatelyadjacent to each section of the gallery 60. The gallery itself ispreferably formed of sections of pre-cast concrete grout, including afloor plate 74 and a safety wall 76 fonned integrally therewith.

Another embodiment of the invention employs prefabricated concretecolumn segments 16? or (FIGS. 14 and 15) in place of the in situ pouredconcrete columns 16, or precast concrete column segments 16R (FIG. 16),which are formed with integrally cast outrigger beam extensions 198, inplace of the in situ poured concrete beams 16 and the outrigger beams 62of FIGS. 7 or 8. Such pre-cast beams are conventional in theconstruction industry, BACKGROUND OF THE INVENTION and are normallyformed in onestory lengths or segments, which are then tied togetherinto a complete column structure extending the full height of thebuilding, by means of interlocking depending steel reinforcing rods 201and upper sockets 203, and the well known post-tensioning technique. Forthe latter purpose the pre-cast column segments 16?, 16Q and 16R areprovided with centrally located hollow liner tubes 200, through whichpass posttensioning bars 202 having threaded ends projecting from thetop and bottom of the pre-cast segments. As each column segment 161, 160or 16R is set in place, grout material is poured into the sockets 203 ofthe lower segment, and the depending rods 201 of the upper segment areinserted thereinto. Then the lower end of the post-tensioning bar 202thereof is anchored by means of a threaded connection to the upper endof the post-tensioning bar 202 of the column segment immediately below,and then the upper end of the posttensioning bar is pulled tight in anupward direction by means of a jack, and anchored to the top of thecolumn segment by a wedge or any other known means.

In the present building, these pre-cast concrete column segments wouldhave laterally projecting haunches or support pads 34? integrally formedat the bottom of each individual casting 161", 160 or 16R. Then, duringthe construction of the building, the column segments are the firstportion of each building level or story to be put in place; i.e., thesegments 161, 160 or 16R for a particular building level are first setin place upon the pre-cast column segments of the level below, afterwhich the modules 12 for the new level are set in place upon the supportpads 341 thereof, and the exterior galleries 60 for the new level areput in place upon the integrally cast outrigger beams 198.

The poured-in-place method has the advantage that it inherently joinsthe columns 16 to the modules 12 so that they are able to perform theirfunction as box beams in the structural framework of the building. Inconnection with FIG. 5, we have already spoken of the downward wedgingaction resulting from the complementary slanting surfaces of the modulewalls 20 and poured concrete column segments 16.2 etc., an effect whichcan be obtained most easily with the poured-inplace method. In addition,however, each column segment such as 16.3 and its laterally projectinghaunches 34, together with the laterally projecting haunches of thecolumn segment 16.2 below it, form a C-shaped pincer formation whichgrasps the adjacent modules 12.5 and 12.6. Furthermore, the pouredconcrete material of the columns 16 and haunches 34 tends to adhere tothe adjacent concrete grout of the module ceiling plate 18, side plate20 and floor plate 22. As a result, there is a sufficiently strongconnection between each module 12 and the columns 16 located at eitherend thereof, to connect them into a rigid structural framework inaccordance with this invention. In addition, one or more of the verticalreinforcing ribs 40 of each module may be embedded in the pouredconcrete columns 16, as in the case of the reinforcing ribs 40.2 in FIG.3, which interlocks the modules and columns to provide additionalrestraint against the possibility of independent movement.

However, when pre-cast concrete column segments 16?, 16Q and 16R areused, it is not possible to achieve such adhesion, since the concretecolumn segments and the grout plates of the modules 12 can only comeinto contact with each other after all have dried and hardened. Inaddition, it is not possible to form the concrete column segments 161,160 and 16R about any of the vertical stiffening ribs 40.2 as describedabove. Accordingly, in order to make a strong column-to-beam connectionbetween the pre-cast column segments and the modules 12, the columnsegments 16? are provided with horizontally projecting tie rods 204 onopposite sides thereof, and the column segments 16R are each providedwith a single such rod 204 on one side thereof (in the latter caseopposite the integrally cast outrigger beam 198). As illustrated in FIG.14, these tie rods are located so that each one of them extends into thehollow of a trough structure 290 projecting upwardly above the junctureof two adjacent modules 12 located adacent to the particular columnsegment and placed on the floor below. This trough hollow is filled withmortar 292, and after the mortar is allowed to harden, the tie rods 204are then rigidly connected to the respective modules 12 on the floorbelow. The opposite ends of the tie rods are embedded in the associatedconcrete column segment at the time of its casting, so that the modules12 and column segments are rigidly tied together in accordance with thestructural requirements stated above. The details of the troughstructure 290 are discussed below in connection with FIG. 13.

The column segment 16R is intended for use on the outside wall of thebuilding, where there are modules on one side only, and therefore no tierods 204 are required on the opposite side. Instead, the individuallycast outrigger beam 198 is required to support the exterior galleries60. On the opposing outside wall of the building, where there are noexterior galleries, a different type of precast concrete column segment160 would be used, which has only two tie rods 204, and which lacks theout-trigger beam 198.

An additional feature of construction, of particular importance in zoneswhere earthquakes are a consideration, is a concrete wall (FIG. 8) whichextends transversely across the mid-section of one or more modules. Asseen in FIG. 9, such an earthquake wall may be formed by pouring liquidconcrete between a pair of transverse module walls 82 defining a pouringcavity 84 between them. The resulting earthquake wall 80 is also formedwith supporting pads or haunches 34 projecting laterally therefrom, forthe purpose of supporting the module 12 immediately above, as in thecase of the haunches formed on the column members At one or more pointsalong the length of the apartment building, it is necessary to devotemodules on each floor to elevator and stairway facilities, as well as atransverse hallway which provides an elevator waiting area, andpreferably also connects with the stair landings. Thus as seen in FIG.9, on each story of the building are three consecutive modules 12.10,12.11 and 12.12 which perform these functions. Although shown in anexploded view, it will be understood that these three modules areinstalled in closely spaced relationship, and are designed to functionas a unit. Moreover, each of the three modules illustrated in FIG. 9 hassimilar modules immediately above and below it in the adjoining stories,with which it cooperate.

Thus, module 12.10 is an elevator shaft module, and is divided into apair of elevator shaft cubicles and 92, assuming that the apartmentbuilding is designed for two elevators. The elevator shaft cubicles 90and 92 are vertically aligned with similar cubicles in similar modulesimmediately above and below, thus defining elevator shafts extendingvertically through the building. The module 12.10 also includes asuperintendents utility room 94 at one end, while at the other end ithas a service chamber 96 which is formed with upper and lower hatches 98and 100 respectively through which various service risers forelectricity, plumbing, etc., may extend vertically through the building.

At the sides of elevator shaft cubicles 90 and 92 are formed elevatordoorways 102 and 104 respectively, and these are horizontally alignedwith elevator doorways 106 and 108 respectively formed in the side ofthe module 12.11. The entire interior of the latter module forms aninterior hallway which is accessible from the exterior gallery 60, sothat users of the building pass through it, and enter the'elevatorsthrough doorways 106, 102 and 108, 104. In like manner thesuperintendent's utility closet 94 is formed with an entrance doorway110 which lines up horizontally with an entrance doorway 112 in themodule 12.11, for access from the interior hallway of the module 111.

Reference numeral 12.12 designates a stairway module having landingareas 114 and 116 at the opposite ends thereof, and two staircases 118between the landings. The staircases 118 of each module 12.12 are inscissors relationship, and connect the landing area 114 of one modulewith the landing area 116 of another module. Stacking the modules 12.12in a vertical bank thus produces a continuous double stairway extendingvertically through the building, just as stacking the elevator shaftmodules 12.10 produces a pair of continuous elevator shafts. Doorways120 and 122 are formed in the modules 12.11 and 12.12 to permit passagefrom the interior hall to the stair landing 114, while a similar pair ofdoorways 124 and 126 connects the hallways with stair landing 116.

Wherever two adjacent modules are required to have interconnectingdoorways, as the cooperating modules do in FIG. 9, or as would be trueof a relatively large apartment suite extends over more than one module,there must be a certain tolerance for both horizontal and verticalmisalignment of confronting doorway openings, due to unavoidable errorsin the placement of modules. Among several solutions to the horizontalmisalignment problem, perhaps the simplest is to make the one of thedoorways in which the door is installed (e.g., doorway 122 in FIG. 9)smaller in the horizontal direction that its cooperating doorway 120. Ifthe size difference is made equal to twice the largest expectedhorizontal misalignment, then even in the event of a maximum horizontaloffset in either direction, the smaller doorway 122 will not bedisplaced beyond the alignment field of the larger doorway 120. Thusfunctional alignment will always be possible, as long as tolerancelimits are not exceeded. Of course the two different-sized doorways cannot meet precisely at both edges of the doorway, and may not meet ateither edge, depending on the exact positioning of the modules; but thisis an esthetic rather than a functional problem. For sealing purposesthere are confronting hoods 123 and 125 entirely surrounding thecooperating doorways 120 and 122 respectively on all four sides, andthese hoods project into close proximity with each other but do nottouch. See FIGS. 9 and 20. Sealing contact is made by an elastomericgasket 127 previously installed within a suitable recess formed in oneof the confronting hood surfaces, for example hood 125.

The extent of vertical misalignment is expected to be fairly small; butnevertheless, in order to prevent tripping, and to cover over the smallgap between hoods 123 and 125 at the bottom of the doorway, there isprovided a walkover plate 250 (FIG. which is bolted to a plurality ofattachment clips 252. These clips grip a flange 251 at the lower edge ofdoorway hood 123. The clips 252 may be released or tightened against theflange by means of bolts 254, which also serve to fasten the plate 250to the clips. When the bolts 254 are sufficiently loosened, the clips252 are released so that the clips and the plate 250 can be advancedtoward or retracted from the hood 125, by sliding horizontally over thelower edge flange 251. Initially these plates are in a retractedposition so as not to interfere with placement of the modules. But afterplacement has been accomplished, the modules are entered for the purposeof advancing the walkover plates 250 into bridging position. Then theyare finally secured in place.

If the inevitable horizontal mismatch between different sized doorwaysis considered esthetically objectionable, the adjustable type ofdoorframe hardware illustrated in FIG. 20 may be employed to cover up.This includes a door buck 260 which is secured by clips 262 to flanges266 formed on both sides of doorway hood 123. These clips are secured bybolts 264, which also serve to attach the buck 260 to the clips 262. Insimilar fashion, door jambs 270 are secured by clips 272 and bolts 274to flanges 275 on both sides of the cooperating doorway hood 125. Afterreleasing the bolts 274 sufficiently, the jambs 270 can be adjustedhorizontally relative to the flanges 276 to line up the jambs with theadjacent section of the buck 260, and then the bolts 274 are tightened.A cover plate 278 is secured to each jamb 270 and is adjustablehorizontally relative thereto by means of bolts 282 and elongated slots280, to more into abutment with the adjacent section of the door buck260. The adjustment of the jambs 270 and cover plates 278, like theadjustment of the walkover plate 250, is accomplished from inside themodules, after they have been set in place.

In accordance with an additional aspect of this invention, the curtainwalls 68 are installed and the doorways 64 leading to the interior ofeach module are sealed at the factory where the module is manufactured,thus preventing workmen from entering the module interiors afterdelivery to the construction site. Another doorway 134, seen in FIGS. 10and 12, leads into a special chamber 136 which is completely partionedoff from the remainder of the module 12; i.e., there is no access fromthe chamber 136 to those rooms of the module which are intended forhuman use or occupancy. Within the latter rooms are various servicefacilities such as electrical outlets, gas lines if a gas stove isinstalled, plumbing fixtures for the delivery of hot and cold runningwater and for waste diSposal and suitable openings for the delivery ofair for heating, air conditioning or ventilation purposes, and/or hotwater radiators for heating purposes if that type of heating system isemployed. From each of these facilities, factoryinstalled service lines141 of the appropriate type, e.g., and electrical cable, a hot or coldwater pipe, a waste disposal pipe, a vent line, a gas pipe, etc., leadthrough the interior of the module and ultimately reach the chamber 136for connection to heating and/or airconditioning unit (if each suite hasits own unit), and/or to service risers 142 within the chamber. The unit140 can be a hot water heater which supplies hot water for washing aswell as for space heating purposes if the latter type of heating systemis employed, and/or a unit which provides heat for a hot air heatingsystem and/or an air-conditioning unit which provides cold air duringthe summer months. The risers 142 would ordinarily include a cold watersupply, waste drain, vent, electrical supply, and a gas or oil fuelsupply, if required for the kitchen stove or heater 140. These servicerisers 142 are field-installed in the chamber 136, and a can beconnected to the heater/air-conditioner unit 140, as well as to all theservice lines 141, by entering the chamber 136. Consequently, no workmenare required to enter the other rooms of the module 12.13. This has theadvantage of keeping those rooms in factory-clean condition during theon-site phase of construction. The first person to enter the other roomsof the module 12 is the first occupant of the apartment suite; yet hefinds complete electrical, plumbing, heating and air-conditioningfacilities completely connected and in operating condition on hisarrival.

If anapartment suite extends over more than one module, and if thehardware of FIG. 20 is employed at

1. A multi-story building of modular construction including a pluralityof modular box beams of substantially similar structural strength, eachsaid beam enclosing at least one room of the interior space of saidbuilding, said box beams being in spaced horizontal layers and in spacedvertical alignment, a plurality of vertical columns for supporting theweight of said box beams, said columns being cast-in-situ in laterallyand longitudinally spaced apart relation and being positioned betweensaid horizontally spaced box beams adjacent the ends thereof box beamsupport members on said columns to receive and support the box beams ofthe story thereabove, said box beams being rigidly bonded to saidsupport members, and said box beams above the ground floor beingsupported substantially entirely upon said support members and havingstrength enough to span the space between said support members withoutsupport from box beams therebelow, whereby said box beams havesubstantially their entire weight carried by said vertical columns.
 2. Amulti-story building as set forth in claim 1 in which said box beamscollectively bear at least the major portion of all horizontalstructural loads of said building in the direction of the longitudinalaxes of said box beams.
 3. A multi-modular building adapted for readyon-site construction through use of pre-fabricated modules of uniformstrength, said building including: a base support, a plurality of layersof box beam room modules, each of said layers including a plurality ofsaid room modules in spaced horizontal relationship, said layers beingpositioned one above another with said room modules in spaced verticalalignment, a series of vertical concrete supporting columns fabricatedof material in a portion of the space between said horizontally disposedmodules, said columns being spaced apart laterally and longitudinally ofsaid modules and positioned near the ends thereof, said supportingcolumns carrying module supporting shoulders for said layers of modulesabove said base, said cast-in-situ supporting shoulders and columnsbearing the weight of the respective modules positioned thereabove andrigidly binding horizontally adjacent modules together, said roommodules having sufficient structural strength to be self-supportingbetween said shoulders, whereby a building is constructed ofsubstantially uniform room modules which do not themselves support theweight of the modules thereabove.
 4. A building as in claim 3 wherein:said box beams have side walls reinforced with a plurality of exteriorvertical ribs, at least some of said ribs of confronting box beam wallsengaging with said cast in situ columns to provide structural rigidity.5. A building as in claim 3 wherein: the width of said columns decreaseswith increasing height of said building.
 6. A building as in claim 3wherein: said box beams comprise side plates formed with a downwardlyincreasing tHickness, and the confronting outer surfaces of said sideplates of horizontally consecutive box beams converge toward each otherin the downward direction, whereby said columns cast-in-situtherebetween taper downwardly to a smaller thickness at the lowerportion of each story than at the upper portion thereof.
 7. A buildingas in claim 3 wherein: horizontal outrigger beams are embedded in saidpoured columns and project beyond said box beams, and an externalgallery is supported upon said outrigger beams.
 8. A building as inclaim 3 wherein: said box beams have side walls reinforced with exteriorvertical ribs, and said cast in situ column material interlocks said boxbeams and columns against mutual displacement along the longitudinalaxis of said box beams.
 9. A building as in claim 1 wherein: saidroom-enclosing box beams also extend between two of said columns in asecond horizontal direction transverse to the longitudinal axis of saidbox beams, and are secured thereto and effective to act as horizontalties between said columns for lending horizontal rigidity to saidframework along said second horizontal direction; and saidroom-enclosing box beams collectively also bear at least the majorportion of all structural loads exerted by said building in said secondhorizontal direction.
 10. A building as in claim 9 wherein saidstructural framework includes no other horizontal structural membersapart from said room-enclosing boxes which are capable by themselves ofbearing the horizontal structural loads exerted by said building.
 11. Abuilding as in claim 10 wherein said structural framework consistsexclusively of said columns and said room-enclosing boxes.